I flew mine to the US from Aus. It just went in a cardboard box, a little bit of cardboard and foam padding and all my assorted bikepacking junk packed around it. I think I calculated that it went through something like 13 different airports during my trip and it was fine although it was more tape than box by the time it made it home.

The only thing I did that was a little different was re-inforce the handle holes on the side of the box with some plastic sheet glued internally. Every time I have had a cardboard box fail, it is where the side of the box is torn open by baggage handlers pulling at the handle holes.

I went from Texas to Portugal once (still riding around in Europe) back in 2004. The airlines told me then if I left the bike assembled then it should not have any issues. When I questioned what they meant by that the lady said if I took off my tires then it would just be thrown around like the rest of the luggage.

Landed in Lisbon and all was well with my bike and started skirting the coastline south that afternoon.

Took many of Military Hops back when I was in the service and never had trouble there either.

I went from Texas to Portugal once (still riding around in Europe) back in 2004. The airlines told me then if I left the bike assembled then it should not have any issues. When I questioned what they meant by that the lady said if I took off my tires then it would just be thrown around like the rest of the luggage.

Landed in Lisbon and all was well with my bike and started skirting the coastline south that afternoon.

Took many of Military Hops back when I was in the service and never had trouble there either.

I flew mine to the US from Aus. It just went in a cardboard box, a little bit of cardboard and foam padding and all my assorted bikepacking junk packed around it. I think I calculated that it went through something like 13 different airports during my trip and it was fine although it was more tape than box by the time it made it home.

The only thing I did that was a little different was re-inforce the handle holes on the side of the box with some plastic sheet glued internally. Every time I have had a cardboard box fail, it is where the side of the box is torn open by baggage handlers pulling at the handle holes.